Dry cell and battery seal



Oct. 18, 1949. A. M. Ma FARLAND I I DRY CELL AND BATTERY SEAL Original Filed April 30, 1941 invention relates cell batteries. This application is a division of "hernia ion-[18,1949

par cELL AND na'r'riiar sun Allison; M; MflQFlfland, Freeport, n1.-,i uam;to 1 Burgess Battery Company, Freeport, 111.,- a corv poratlorro! Delaware 7 Claims. (Cl. 136-133) 391,109, now.

to improvements in dry the co-pending application of Allison-M. Mac- Farland, Serial No. 391,109, filed April 30, 1941,

now Patent No. 2,389,674, dated November 2'7;

The-ordinary dry cell of the cylindrical type consists of a zinc can containing a central carbon rodelement which forms one electrode, a depolarizing mass between the carbon and'the zinc and insulated from the latter, and a suitable is'electricallyconductive, and the zinc can. The can may be provided with'an integral metalliczbottomor may be a-cylinder open at both ends such, for example, as that describedxin C. F. Burgess PatentjNo. 2,231,320. The metal can formsthe second electrode. It is ordinarily closed at the bottom and open at the top. I After the active mass, including the carbon electrode, depolarizing mix, and electrolyte, have been inserted in the can during assembly of the cell, the customary practice is to place a paper washer on .the carbon rod to support a seal of-wax, pitch, or other thermoplastic or fusible sealing material which closes the open end of the can. A space is left between the depolarizing mass and the washer to provide an expansion chamber into which gases and liquids formed during operation of the cell may escape. The sealing material is ordinarily poured in fluid condition on to the paper washers, each cell being thus individually provided with a seal.

The principal objects of the invention are to simplify the process of manufacturing dry cells and dry batteries and thereby reduce the cost of the finished article, and to avoid the dangers of using paper washer seal supports, as, for example, the short-circuiting of the cell due to saturation of the paper by electrolyte. This general objective is achieved by eliminating the paper washer-and the steps of applying the washer and pouring the sealing material into the cells, a single, simple sealing operation being substituted as hereinafter more fully described. A groupofcells may be sealed and joined together into a unitary battery block by means-of a single sealing operation. The connecting wires and soldered connections are protected by the same sealingoperation.

Furtherfobjects of the invention include the provision of a cell which is completely encased within an inert jacket which prevents escape of corrosive materials from the interior of the cell;

also,': the provision or a cell having an expansion electrolyte betweenthe depolarizing mass, which 1941, Serial No.

chamber in either end'there'of with provision for v the relief of pressureswhichimay build up in the expansionchambers;

The. many features of advantage in the-new method and-product disclosed herein will becomeapparent as thedescription; proceeds.

Fig. 1 is a perspective view, -partly in section, of a dry battery constructed, in accordance with the present invention; I v

Figs. 2, 3,'and- 4 illustrate,;i'n .transverse section, the battery of 1"lg.i1,'or'parts thereof; in three stages of-'manufacture; *the .cellsbeing shown-partly in sectiony'and'j g Fig. 5 illustrates, in perspective, partly in section, a single cell unit embodying-the-invention.

The battery of Fig. 1, shown by way of illustration of a particular embodiment of the invention, is formed from a plurality of dry cells I housed within a container formed by trays 2 and 3. These trays are ordinarilyof: cardboard impregnated with paraffin or other suitable impregnant, thismaterial being customarily used for covering in the battery manufacturing art. The cells I are connectediin series by means of connecting wires 4,.battery leads 5 and 6 being provided for connection of the external circuit with the end cells of the series. The invention, however, is applicable to all batteries, whether of the A, B, or C type. Thermoplastic or fusible seals 1 and la are used to close the ends of the cells, join them together into a firm block; and protect the connecting wires 4 and the soldered connections of these wires with the car- The individual cells are preferably provided with jackets l3 of inert fllm'material. These jackets are cylindrical in form, snuglyenvelop the metal tubes 9, and extend slightly beyond the open ends of the tubes. They are'preferably composed of a material which is electrically insulatmg, somewhat elastic inthe sense that it may be stretched without rupture,'-and resistant to the corrosive salts and solutions contained in. the active masses of the cells-.'- P1ioillm," a rubber. hydrohalide, rubber, .ethylcellulose,. and

polystyrene are suitable materials The jackets may be applied to-the c ells-'in anydesired manaccess? to harden, then repeating the process to seal the other'ends oithe cells. This may be done in several diflerent ways all oi which involve the essential ieatureoi lowering theinverted cells into the-sealing material as contrasted with the present common practiceoi pouring the fluid sealing material into the tops of the individual upright cells. .The sealing material need not be liquid but should-be sufllciently fluid to flow around the cells readily. I

In the preferred method, the necessary number or cells are assembled in a suitable form which is adapted to hold them upright and in the form which the battery block will ilnally assume. Tray 2 may be used for this purpose. The necessary electrical connections are then made between the cells and the battery leads I and t are soldered at the proper terminal points. The battery block is then inverted a lowered (as indicated by the arrow, Fig. 3) into cover tray 3 which contains a shallow body of fluid sealing materials I as shown in lfig. 2. This operation isillustrated in Fig. 3. Leads I and 6 are brought out as the wired ends of the cells enter tray I- to be available for connection to the battery terminal posts, not shown. Any suitable sealing-material may be used, although. it is preferable, for the reasons hereinafter stated, to use a substance which will remain somewhat plastic at normal temperatures at which the battery is to be operated. The'sealing material I is hot and therefore relatively'fluid when the battery block is lowefied into it. Asthe cells enter'the body oi sealing material, it is torced'up around and between the cells. results from the displacement of the material bythe cells, since the sealing material extends into the interior of the cells only slightlybecause of the air pressure in the spaces at the ends of the cells which are completely closed upon engagement of the ends oi the jacketswiththe-sealing material. In'this way, the seal is caused to rise around'the cells to a point determined by the original depth 01 the body of thermoplastic material and the depth of immersion of the cell block into it.

Following this sealing operation, the sealing material is permitted to cool and the partly sealed batte y. from which the temporary form I has been removed, may be inverted and lowered into tray 2 into which has been poured a quantity of fluid sealing material la. This step is illustrated in Fig; 4. The battery is now completely sealed and covered. When the sealing material has completely cooled, the battery is solid and still. There is no opportunity for air pockets or bubbles: toi'orm in the sealing material or be: tween it and the cover trays. Outer surfaces are smooth and cemented to the seal; The'individual cells are completely closed. Leads 5 and 6 may be brought out between the'cover trays of the battery where they will be available for the application of suitable terminal posts or clips. The joint between trays 2 and I may be sealed with a suitablegummed tape. if desired.'

fluid sealing material 2|.

contained in thin paper liners supported by suitable forms, the p per either being removed or allowed to remain in place before the battery is placed in 'an.outer' covering; or, the. vindividual cells may be assembled in the first instance in -a tray which is to form a part of the permanent covering and which contains the sealing material. In the latter case, the tray should be kept on a hot surface until all the cells have been placed in the form. The sealing would then be completed alter the cells had been connected together by lowering the top portion into the second cover tray containing fluid sealing material.

As above indicated. the entrapped air at the ends or the cells provide expansion chambers in the finished product. It the cell jackets terminate at the ends of the tubes, or only very slightly beyond, the sealing material will reach at least the ends of the tubes so that the expansion chambers are entirely within the tubes. If, however, the jackets extend a substantial distance beyond the ends of the tubes, say $4; to inch, the greater part of the expansion chambers may bewithin the jacket extension and beyond the ends of the tubes. If a sealing material which remains somewhat plastic atnormal temperatures] is used and if the jacket material is elastic, a means is provided for the relief of excessive pressures which may occur in the expansion chambers during unusually heavy electrical drain periods. Both the plastic sealing material and the jacket will give, as a result of the force of the gas pressure, so that the gases may escape between the metal tube and the jacket into spaces between the cells formed by the stretching of the jackets along the mid-portions of the cells. Considerable volumes of gases may be accommodated in this way without rupturing theprotective cell casings.

illustrated in Fig. 5. This unit may be assembled in a manner similar to that above described. The cell comprises a metal tube It containing an active mass II and covered by a jacket 16 of inert fllm material. As indicated in the drawins. Jacket it extends a considerable distance beyond the end of can ll. Leads II and I8 connect with the two electrodes of the cell. An expansion chamber I9 is provided within the portion of jacket ll which extends beyond the metal tube 01' the cell when the cell is lowered into a box 20 which contains a small amount of The carbon 22 of the cell is preferably or sufllcient length to cause it to extend into the sealing material to thereby does not reach the tube. As pointed'out-above, v

this arrangement permits Bases to escape from expansion chamber it between tube It and jacket it into the space between the cell and outer box.

' 20 as the jacket is stretched. a

' In addition to the economies in manufacture resulting from the present invention, many other advantages are evident. The carbon electrodes are not disturbed by the sealing operation, whereas the application of a relatively stiff paper washer in prior practices may cause a shifting of the carbon and consequent impairment of electrical contact with the depolarizing material. The invention is applicable to the sealing of cells having cans with integral metal bottoms although such cells are not illustrated in the drawing. Such cells need not be similarly oriented in the battery block; that is, part of the cells may open at the top of the block while others may be inverted and open downwardly.

I claim:

1. A dry cell having a metal tube open at at least one end thereof and within which is arranged an active mass, a jacket of inert film material around said tube and extending beyond an open end thereof and means for forming an expansion chamber within the portion of said jacket extending beyond said tube, said means comprising a gas-tight plug of sealing material within the portion of said jacket extending beyond said tube and spaced from the end of said tube, said sealing material being directly exposed to the space within said chamber.

2. A dry cell in accordance with claim 1 in which said inert film material is elastic.

3. A dry cell having a metal tube open at one end thereof and within which is arranged an active mass, said mass occupying only a portion of the volume of said tube whereby an unfilled portion is left adjacent the open end thereof, a jacket of inert film material around said tube and extending beyond the open end thereof, and means for forming an expansion chamber within the portion of said jacket extending beyond said tube and the unfilled portion of said tube, said means comprising a gas-tight plug of sealing material within the portion of said jacket extending beyond said tube and spaced from the end of said tube, said sealing material being directly exposed to the space within said chamber.

4. A dry cell having a metal tube open at at least one end thereof and within which is arranged an active mass, a jacket of elastic inert film material around said tube'and extending beyond an open end thereof, means for forming an expansion chamber within the portion of said jacket extending beyond said tube, said means comprising a body of sealing material completely closing the end of said jacket and spaced from the end of said tube within said jacket, said sealing material substantially enclosing said portion a Number 6 of said jacket extending beyond said tube and being directly exposed to the space within said chamber.

5. A dry cell in accordance with claim 4 in which said sealing material remains plastic at normal temperatures.

6. A dry cell having a metal tube open at at least one end thereof and within which is arranged an active mass, 8. jacket of elastic inert film material around said tube and extending beyond an open end thereof, means for forming an expansion chamber within the portion of said jacket extending beyond said tube, said means comprising a body of sealing material surrounding the portion of said jacket extending beyond the open end of said tube and also at least a part of said tube and completely closing the open end of said jacket, said body of sealing material being spaced from the end of said tube within said jacket and being directly exposed to the space within said chamber, said sealing material remaining plastic at normal temperatures.

7. A dry battery comprising a plurality of electrically connected cells nested .within a container of sheet material, each of said cells having an expansion chamber at at least one end thereof. a layer of sealing material lining the wall of said container adjoining the expansion chamber ends of said cells, and a jacket of inert film material on each cell extending into the sealing material, said sealing material forming a bounding surface of the expansion chambers.

- ALLISON M. MAOFARLAND.

'acrcanncas crrnn The following references are of record in the file of this patent:

' UNITED'B'I'ATIS PATENTS FOREIGN PATENTS Country Great Britain Number Date May 3, 1924 Date 339,799 Dec. 18, 1930 Jan. 3, 1922 I 

